Engine



Dec. 6, 1960 D. F. CARlS 2,963,015

ENGINE Filed Feb. 24. 1958 s Sheets-Sheet 1 INVENTOR. I fizz/75am .4

ATTORNEY Dec. 6, 1960 D. F. CARIS 2,963,015

ENGINE Filed Feb. 24, 1958 s Sheets-Sheet 2 Dec. 6, 1960 D. F. cARls2,963,015

ENGINE Filed Feb. 24. 1958 3 Sheets-Sheet 5 1 V VETO R.

W My (Z7213 United States Patent 2,963,015 ENGINE Darl F. Caris,Bloomfield Hills, Mich., assignor to General Motors Corporation,Detroit, Mich., a corporation of Delaware Filed Feb. 24, 1958, Ser. No.717,246

'8 Claims. (Cl. 123-193) .The present invention relates to internalcombustion engines and more particularly to laminated cylinder headstructures therefor.

-Heretofore, it has been customary to employ cast iron cylinder heads oninternal combustion engines. These heads are normally cast aroundtemporary sand cores with which it is difficult, if not impossible, tocast the various surfaces with sufiicient accuracy. As a result, it isfrequently necessary to machine the combustion chambers and otherportions. Also, cast iron is excessively heavy as well as a relativelypoor conductor'for dissipating the heat from the burning gases.

In order to overcome the above objections, numerous attempts have beenmade to devise an economical and practical means for producing cylinderheads of lightweight alloys such as aluminum or magnesium which arecomparatively good conductors of heat. However, due to the intricatepassages and surfaces in the cylinder head, it has been necessary tocast the structure with expendable sand cores in substantially the samemanner as employed in connection with the cast iron cylinder heads orelse to weld or solder several pieces together. This is unsatisfactorydue to the cost and production problems involved.

It is now proposed to provide a novel means for producing a new cylinderhead which is particularly adapted to be die cast. More particularly,the cylinder head comprises at least two members that are adhesivelybonded together by any suitable thermal setting plastic material such asan epoxy resin. Each of these members has cavities arranged therein sothat when they are bonded together, they will form the various intakeand exhaust passages and cooling cavities contained in the cylinderhead. The members separate along surfaces arranged with the surfaces ofthe cavities complementary to the exterior of permanent cores so as topermit full advantage to be taken of the characteristics of the metals.

' In the drawings:

Figure 1 is an end view, with a portion thereof being broken away, of anengine employing cylinder heads embodying the present invention.

Figure 2 is a transverse cross-sectional view of a cylinder heademployed in the engine of Figure 1.

Figure 3 is a fragmentary plan view showing a portion of the top of thecylinder head.

Figure 4 is a fragmentary cross-sectional view of an engine employing acylinder head embodying a different form of the present invention.

Referring to the drawings in more detail, although this invention may beembodied in any type of engine 10, it is particularly adapted for use inan internal combustion engine of the so-called V-type such as disclosedand claimed in Serial No. 716,904, filed February 24, 1958.

The present engine includes a cylinder block 12 hav ing a pair ofangularly disposed banks 14 and 1-6 of cylinders 18.

top of the cylinder bank 14 or 16 while the inner ends The cylinders 18extend through the block. with the outer ends forming openings in theface 20 on 2,963,015 Patented Dec. 6, 1960 2 open into the crankcase. Apiston 21 is reciprocably disposed in each of the cylinders 18 and isoperatively interconnected With a rotating crankshaft by a connectingrod of any suitable form.

A laminated cylinder head 22 is secured by bolts to each of the faces 20on the cylinder block 12 to close the ends of the cylinders 18 and formcombustion chambers. An induction system 24 is disposed between the twoheads 22 for supplying a combustible mixture of air and fuel for thecombustion chambers. This system 24 includes an intake manifold 26having the opposite sides 28 thereof secured to the inboard sides 30 ofthe cylinder heads 22.

A carburetor 32 is mounted on top of the manifold 26 i and a pluralityof distribution passages extend through the manifold 26 to ports in thesides thereoffor distributing the charge to the combustion chambers.

The cylinder head 22 is a laminated structure which includes a firstmember 36 and a second or backing mem- I ber 38. One side of the firstmember 36 has a plane surface 42 for engaging the face 20 on thecylinder block 12. Portions 44 of this surface 42 close the open ends ofthe cylinders 18 to thereby form suitable combustion chambers. Ifdesired, the portions 44 may be recessed into the surface to give thecombustion chamber any desired shape.

The backing member 38 includes a surface 46 complementary to a secondsurface 48 on the backside of the ject the entire head 22 totemperatures which might adversely affect the characteristics of themetal or cause thermal distortions in the finished head 22.

Separate intake and exhaust passages 50 and 52 are provided for each ofthe cylinders 18. The intake passages 50 extend transversely of thecylinder head structure 22 so that the outer ends of the passages 50form intake ports 51 in faces 30 registering with the ports in the sides28 of the manifold 26, while the inner ends form valve seats 54 openinginto the combustion chambers. The inner ends of the exhaust passages 52form exhaust valve seats 56 communicating with the combustion chamberswhile the outer ends form exhaust ports 58 for discharging exhaust gasesinto exhaust manifolds 60 on the opposite sides of the engine 10.

Intake and exhaust valves 62 are provided with the stems 64 thereofdisposed in the valve ides 66 and the heads thereof in the valve seats54 or 56 to thereby control the charging and exhausting of the cylinders18. Rocker arms 67 are pivotally mounted on top of the backing member 38so that the ends thereof will bear on the ends of the valve stems 64.The rocker arms 67 may be mounted on a shaft or on the ends of studs 69press fitted into the backing member 38. The opposite ends of the rockerarms 67 bear on the ends of push rods 70 actuated by a rotating camshaftin the cylinder block 12 for controlling the opening and closing of thevalves 62. The push rods 70 extend through clearance spaces 72 in thecylinder heads 22 and cylinder block 12.

A cooling cavity 74 is provided in the cylinder head 22 to contain asuitable coolant to be retained in intimate heat absorbing relation withthe combustion chamber, valve seats 54 and 56 and intake and exhaustpassages 50 and 52. This cavity 74 is interconnected with the jacket inthe cylinder block 12 so that coolant may flow therebetween and maintaina controlled temperature in the working parts of the engine.

Each of the members 36 and 38 of the cylinder heads 22 is arranged to bedie cast from a lightweight material such as an alloy of aluminum ormagnesium. To facilitate the die casting the intricate passages andcavities are formed to be complementary to non-collapsible cores whichmay be pulled in straight lines from the cavities. For example, each ofthe intake passages 50 includes a section 76 around the intake valveseat 54 and a section 78 extending from the end of the first section 76to the intake port 51. The first section 76 includes a portion 88 thatextends completely through the first member 36 and a portion 82 thatextends part-way into the backing member 38 to terminate around thevalve guide 66. The portion 80 of the passage through the first member36 is tapered complementary to the exterior of a permanent core whichmay be an integral part of a mold with which the plane surface 42 andcombustion chamber may be formed. It a core is employed, the core may beremoved along a straight line substantially normal to the surface 42. Inaddition, the first section also includes a portion 82 around the valveguide 66. The surface of this portion 82 is tapered to be complementaryto the exterior of a permanent core that may be pulled in a straightline normal to the surface 46 of the backing member 38. This core may bean integral part of the mold for the bottom surface on the backingmember 38. The second section 78 of the intake passage 50, which extendsfrom the area of valve guide 66 to the port 51, includes a surfacecomplementary to a second permanent core that may be employed to engagethe inner end of the first core and to be pulled in a straight line fromthe inboard side 30 of the cylinder head 22 together with the mold forthis side 30.

The exhaust passage 52 is similar to the intake passage 50 and includesa first section 84 around the exhaust valve seat 56 and a second section86 which extends from the first section 84 to the outboard side 88 ofthe cylinder head 22. The first section 84 includes a substantiallystraight portion 90 extending completely through the first member 36.This portion 90 is preferably tapered to allow the core to be pulled ina straight line downwardly from the member 36. It is thus apparent thecores for portions 80 and 90 of the intake and exhaust passages 50 and52 through the first member 36 may be integral with the mold for thesurface 42 of the first member 36. The remaining portion 92 of the firstsection 84 or the portion in the second member 38 is complementary tothe exterior of a permanent core tapered to be pulled in a straight linedownwardly from the passage 52. It is thus apparent that these parts ofthe exhaust cores may be removed on lines parallel to the cores for thecorresponding parts of the intake passages 50. Thus these cores may bean integral portion of the mold for the surface 46 of the second member38.

The cooling cavity 74 comprises a plurality of chambers disposed in heatexchanging relation with the combustion surface and portions of theintake and exhaust passages. These chambers are formed by cavities 94and 96 that are recessed into the mating surfaces 46 and 48 on the twomembers 36 and 38 so as to extend in opposite directions from the jointor split line therebetween. The cavities 94 on the back surface 48 ofthe first member 36 are tapered to permit the use of permanentnon-collapsible cores. These cores are preferably pulled in directionssubstantially normal to the plane of the surface 48 so that they may bean integral part of the mold for the surface. The cavities 96 in thebacking member 38 are preferably tapered to permit'the cores therefor tobe an integral part of the mold for the surface 46 of the backing member38 and removable in directions parallel to the first sections 76 and 84of the intake and exhaust passages 50 and 52. An outlet 98 from thecooling jacket 74 may be formed by a core on the mold for the side 30 ofthe head 22. This core is tapered similar to the cores for the secondsections 78 of the intake passages 50 and intersect the cores for thecavities 96 in the surfaces 46.

The clearance spaces 72 for the push rods 70 may be cored in a mannersimilar to that for the other passages. However, due to various designconsiderations, it may be desirable for the axes of these spaces to beoblique to the surfaces of the molds. Accordingly, a harness 100 may beinserted into the mold with tubes 102 disposed in position to be alignedwith the clearance spaces 72. Thus the clearance spaces 72 will becontinued through the heads 22 by the tubes 102 molded into the headsand secured therein by inter atomic diffusion of the metallic structuresof the hermetically united parts.

As an alternative the structure shown in Figure 4 may be employed. Thiscylinder head 104 is particularly adapted to be employed on an enginesimilar to that disclosed in Figure l. The head 104 includes a firstmember 106 having a plane surface 108 on one side thereof that isadapted to fit onto the face 110 of the cylinder bank 112. This surface108 includes recessed portions 114 adapted to register with the openends of the cylinders and form combustion chambers. The opposite orbackside of this member 106 includes a surface 116 adapted to have acomplementary surface 118 on a first backing member 120 adhesivelybonded thereto by a suitable thermally setting plastic. The backingmember 120 also includes a second surface 122 adapted to have a secondbacking member 121 secured thereto. A cover member 124 is adhesivelybonded to the second backing member 120. The intake passages, exhaustpassages, the cooling cavity 130 and the spaces for the push rods, etc.are formed by registering cavities in the surfaces on these members 106,120, 121 and 124. Each of these cavities is arranged to be complementaryto a core forming an integral portion of the mold for the surface intowhich the cavity is recessed. By employing more than two members infabricating the head 104, any desired shape can be given to thepassages, etc. while still die casting all of the parts. A rocker armshaft 136 is mounted on the cover member 124 by a bracket 137 andincludes rocker arms having one end thereof bearing on the stems of thevalves and the other ends thereof bearing on the push rods. Thusrotation of the camshaft will reciprocate the push rods which, in turn,

will open and close the intake and exhaust valves. The cylinder headassembly 104 is secured in position by a plurality of bolts 138 which,preferably, extend through the entire assembly 104 and compress all ofthe joints together.

What is claimed is:

l. A cylinder head for an internal combustion engine having a cylinderblock with a cylinder extending therethrough and forming an opening inone side thereof, said cylinder head comprising a pair of members havingcomplementary surfaces on adjacent sides thereof and having inlet andexhaust passages formed therein to communicate with said cylinder, atleast one of said passages being formed to extend through saidcomplementary surfaces, one of said pair of members also being formed toprovide a face complementary to said one side of said block and beingadapted to close said cylinder opening, said complementary surfacesbeing adhesively bonded and securing said members together and sealingsaid passages against leakage of fluid to or from said passages, saidhead also embracing means adapted removably to secure said head to saidblock with said face engaging said one side of said block and closingsaid cylinder opening and with said inlet and exhaust passagescommunicating with said cylinder.

2. A cylinder head for an internal combustion engine having a cylinderblock with a cylinder extending therethrough and forming an opening inone side thereof, said cylinder head comprising a pair of members havingcomplementary surfaces on adjacent sides thereof and having inlet andexhaust passages formed therein to communicate with said cylinder, atleast one of said passages being formed ,to extend through saidcomplementary surfaces, ne of said pair of members also beingformed toprovide a face complementary to said one side of said block and beingadapted to close said cylinder opening, said com plementary surfacesbeing adhesively bonded and securing said members together and .sealing'said passages against leakage of fluid to or from said passages, saidhead also embracing means in addition to said bonding and securing saidmembers together on said complementary surfaces and adapted removably tosecure said head to said block with said face engaging said one side ofsaid block and'closing'said cylinder opening and with said ilnlet andexhaust passages communicating with said cylin- 3. A cylinder head foran internal combustion engine having a cylinder block with a cylinderextending there through and forming an opening in one side thereof, saidcylinder head comprising a pair of members having complementary surfaceson adjacent sides thereof and having inlet and exhaust passages formedtherein to communicate with said cylinder, said passages and saidcavities being formed to extend through said complementary surfaces, oneof said pair of members also being formed to provide a facecomplementary to said one side of said block and being adapted to closesaid cylinder opening, said complementary surfaces being adhesivelybonded and securing said members together and sealing said passages andcavities against leakage of fluid to or from said passages and cavities,said head also embracing means adapted removably to secure said head tosaid block with said face engaging said one side of said block andclosing said cylinder opening and with said inlet and exhaust passagescommunicating with said cylinder.

4. A cylinder head for an internal combustion engine having a cylinderblock with a plurality of cylinders extending therethrough and formingopenings in one side thereof, said cylinder head comprising a pair ofmembers having complementary surfaces on the adjacent sides thereof andhaving inlet and exhaust passages formed therein to communicate withsaid cylinders and having coolant cavities formed therein to 0001 saidcylinders, said passages and said cavities being formed to extendthrough said complementary surfaces, one of said pair of members alsobeing formed to provide a face complementary to said one side of saidblock and being adapted to close said cylinder openings, saidcomplementary surfaces being adhesively bonded and securing said memberstogether and sealing said passages and cavities against leakage of fluidto or from said passages and cavities, said head also embracing meansadapted removably to secure said head to said block with said faceengaging said one side of said block and closing said cylinder openingsand with said inlet and exhaust passages communicating with saidcylinders.

5. A cylinder head for an internal combustion engine having a cylinderblock with a plurality of cylinders extending therethrough and formingopenings in one side thereof, said cylinder head comprising a pair ofmembers having complementary surfaces on the adjacent sides thereof andhaving inlet and exhaust passages formed therein to communicate withsaid cylinders and having coolant cavities formed therein to cool saidcylinders, one of said pair of members also being formed to provide aface complementary to said one side of said block and being adapted toclose said cylinder openings, said inlet and exhaust passages beingadapted to open into said cylinders through ports in said complementaryface and to extend axially outwardly of said cylinders through said oneof said pair of members and into the other of said pair of members andthereafter to extend laterally through said other of said pair ofmembers and to terminate in ports in at least one side of said other ofsaid pair of members, said coolant cavities also being formed to extendthrough said complementary surfaces, said complementary surfaces beingadhesively bonded and securing said members together and sealing said--passages and cavities against leakage of fluid to or from said passagesand cavities, said head also embracing means removably securing saidhead to said block with a said face engaging said one side of said blockand clostending therethrough and forming openings in one side thereof,'said cylinder head comprising a pair of mem;

bers having complementary surfaces on the adjacentsides thereof andhaving inlet and exhaust passages formed therein to communicate withsaid cylinders and having coolant cavities formed therein to cool saidcylinders, one of said pair of members also being formed to provide aface complementary to said one side of said block and being adapted toclose said cylinder openings, said inlet and exhaust passages beingadapted to open into said cylinders through ports in said complementaryface and to extend axially outwardly of said cylinders through said oneof said pair of members and into the other of said pair of members andthereafter to extend laterally in opposite directions through said otherof said pair of members and to terminate in ports in opposite sides ofsaid other of said pair of members, said coolant cavities also beingformed to extend through said complementary surfaces, said complementarysurfaces being adhesively bonded and securing said members together andsealing said passages and cavities against leakage of fluid to or fromsaid passages and cavities, said head also embracing means removablysecuring said head to said block with said face engaging said one sideof said block and closing said cylinder openings and with said inlet andexhaust passages communicating with said cylinders.

7. A cylinder head for an internal combustion engine having a cylinderblock with a cylinder extending therethrough and forming an opening inone side thereof, said cylinder head comprising a pair of members havingcomplementary surfaces on adjacent sides thereof and having inlet andexhaust passages formed therein to communicate with said cylinder, oneof said pair of members also being formed to provide a facecomplementary to said one side of said block and being adapted to closesaid cylinder opening, inlet and exhaust valve seats in said one of saidmembers at the ends of said passages and adapted to communicate withsaid cylinder, inlet and exhaust valves controlling said passages andengaging said seats, said valves having stems extending transverselythrough said members, the other of said members being formed to providevalve guide means engaging said valve stems and supporting said valvesin said head, adhesive bonding means securing said members, together andoperatively supporting said guides with respect to said seats, and meansadapted removably to secure said head to said block with said faceengaging said one side of said block and closing said cylinder openingand with said inlet and exhaust passages communicating with saidcylinder.

8. A cylinder head for an internal combustion engine having a cylinderblock with a cylinder extending therethrough and forming an opening inone side thereof, said cylinder head comprising, a pair of membershaving complementary surfaces on adjacent sides thereof and having inletand exhaust passages formed therein to communicate with said cylinder,one of said pair of members also being formed to provide a facecomplementary to said one side of said block and being adapted to closesaid cylinder openings, inlet and exhaust valves disposed in said headand extending across said complementary surfaces, said valves having theseats thereof formed in one of said members and the guides thereforformed in the other, means adhesively bonding said complementary surfaceto secure said members together, and means for removably securing saidhead to said block References Cited in he file of this patent UNITEDSTATES PATENTS 5 Willi Nov. 10, 1936 Genn Apr; 18, 1944 Sheppard Oct.12, 1948 McGuwan et a1. June 7, 1949 10 Klotsch Dec. 27, 1949 SheppardJune 6, 1950 Weslake Dec. 23, 1952 Nallinger Sept. 29, 1953 Brill Jan.10, 1956 Mitchell June 12, 1956 Hands July 10, 1956 Boghossian Oct. 23,1956 Nordenson July 22, 1958 Pierce Mar. 24, 1959 FOREIGN PATENTS FranceJune 30, 1930

